Process for the production of polyepoxy silicate resins

Abstract

Alkali metal aldehyde lignin-cellulose silicate polymers are reacted chemically with an epihalohydrin compound to produce a polyepoxy silicate resin; the polyepoxy silicate resin may be cured by a catalyst, e.g., an amine or Lewis acid, to produce a cured epoxy resin, solid or cellular solid product which may be used as an adhesive, as construction sheets, etc.

I claim: 
     
       1. The process for the production of aldehyde lignin-cellulose silicate polyepoxy resin by mixing and reacting the following components: A.: Polyfunctional epoxide compound, 10 to 200 parts by weight,   B.: Alkali metal aldehyde broken down lignin-cellulose silicate polymer, 50 parts by weight.   
     
     
       2. The process of claim 1 wherein the polyfunctional epoxide compound is selected from the group consisting of epichlorohydrin, epibromohydrin, methyl epichlorohydrin, di-epi-iodohydrin, epifluorohydrin, epi-iodohydrin and trichlorobutylene oxides. 
     
     
       3. The process of claim 1 wherein the polyfunctional epoxide compound is epichlorohydrin. 
     
     
       4. The process of claim 1 wherein up to 200 parts by weight of water are added to the alkali metal aldehyde broken down lignin-cellulose silicate polymer before adding the polyfunctional epoxide compound. 
     
     
       5. The process of claim 1 wherein the aldehyde broken down lignin-cellulose silicate polyepoxy resin is cured by heating. 
     
     
       6. The process of claim 1 wherein an additional step is taken wherein a curing agent in the amount of up to 200 parts by weight, selected from the group consisting of an organic amine, Lewis acids, alkali metal oxides and hydroxides, and mercaptan-terminated liquid compounds, is added to 100 parts by weight of the aldehyde broken down lignin-cellulose silicate polyepoxy resin. 
     
     
       7. The process of claim 6 wherein the curing agent is diethylenetriamine. 
     
     
       8. The process of claim 1 wherein up to 50 parts by weight of a polyhydroxyl compound are mixed with Components A and B before reacting. 
     
     
       9. The process of claim 8 wherein the organic polyhydroxy compound is selected from the group consisting of di(monohydroxy) alkanes, di(monohydroxyaryl)alkanes, resorcinol, hydroquinone glycols, glycerol, trimethylol propane, polyesters with 2 or more hydroxy groups per molecule, polyethers with 2 or more hydroxyl groups per molecule, polyamide with 2 or more hydroxyl groups per molecule, and mixtures thereof. 
     
     
       10. The process of claim 8 wherein the organic polyhydroxy compound is Bisphenol-A. 
     
     
       11. The process of claim 1 wherein up to 50 parts by weight of a phenol compound, selected from the group consisting of phenol, cresole, cresylic acid, creosote, xylenols, cashew nutshell liquid, anacordol, p-tert-butyl phenol, p-tert-anyl phenol, phenolic acids produced from bark and mixtures thereof, are added for each 50 parts by weight of Component B. 
     
     
       12. The process of claim 1 wherein an additional step is taken wherein up to 100 parts by weight of a polyepoxy compound are mixed with 50 parts by weight of the aldehyde broken down lignin-cellulose silicate polyepoxy resin, then mixed with a curing agent up to an amount by weight equal to the weight of the mixture, thereby producing an aldehyde broken down lignin-cellulose silicate epoxy product. 
     
     
       13. The process of claim 12 wherein the curing catalyst is selected from the group consisting of an amine, a Lewis acid, and a mercaptan-terminated liquid compound. 
     
     
       14. The process of claim 1 wherein an additional step is taken wherein 100 parts by weight of the aldehyde broken down lignin-cellulose silicate polyepoxy resin are mixed with up to 100 parts by weight of a phenoxy resin; then up to 200 parts by weight of a curing agent are admixed at a temperature wherein the mixture is in a liquid state, thereby producing an epoxy product. 
     
     
       15. The process of claim 14 wherein the curing agent is selected from the group consisting of an amine, a Lewis acid and a mercaptan-terminated compound. 
     
     
       16. The process of claim 14 wherein the curing agent is a Lewis acid. 
     
     
       17. The process of claim 12 wherein the polyepoxy compound is a glycidyl ether of a polyhydric compound of the group consisting of polyhydric alcohols and polyhydric phenols. 
     
     
       18. The process of claim 12 wherein the polyepoxy compound is a glycidyl polyether of 2,2-bis(4-hydroxy phenyl) propane, containing at least 2 epoxy radicals per molecule. 
     
     
       19. The product produced by the process of claim 1. 
     
     
       20. The product produced by the process of claim 4. 
     
     
       21. The product produced by the process of claim 6. 
     
     
       22. The product produced by the process of claim 8. 
     
     
       23. The product produced by the process of claim 11. 
     
     
       24. The product produced by the process of claim 12. 
     
     
       25. The product produced by the process of claim 13. 
     
     
       26. The process of claim 1 wherein up to 50 parts by weight of a halohydrin compound, selected from the group consisting of alkene halohydrins, are added with Components A and B. 
     
     
       27. The process of claim 26 wherein the halohydrin is ethylene chlorohydrin. 
     
     
       28. The product produced by the process of claim 26. 
     
     
       29. The process of claim 1 wherein an amine catalyst in the amount of up to 200 parts by weight is added with Components A and B. 
     
     
       30. The process of claim 29 wherein the amine catalyst is a tertiary amine. 
     
     
       31. The product produced by the process of claim 29. 
     
     
       32. The process of claim 1 wherein up to 100 parts by weight of a mono-epoxide compound, selected from the group consisting of ethylene oxide, propylene oxide, butylene oxide, tetrahydrofuran styrene oxide or mixtures thereof, are added with Components A and B at a pressure wherein the mono-epoxide compound is in a liquid state or a compressed state. 
     
     
       33. The product produced by the process of claim 32. 
     
     
       34. The process of claim 1 wherein up to 100 parts by weight of an organic compound, selected from the group consisting of organic hydroxy compounds, organic polyhydroxy compounds, organic mono-epoxide compound, halohydrin compounds, organic polyepoxy compounds, and mixtures thereof, are added with Components A and B, at a pressure wherein the organic compound is in a liquid state or a compressed state. 
     
     
       35. The product produced by the process of claim 34.